George Weston Bakeries (now part of Bimbo Bakeries USA) previously engaged The Austin Company for the design-build of their new bakery facility in Elkhart, Indiana. When the original building was designed, space between two production lines was provided for later installation of a third bun line. When the time came for the third production line, Bimbo awarded Austin the design-build project, in addition to services for a 23,000 SF expansion of the facility packaging area and shipping dock.
The expansion project involved relocating all of the existing shipping docks and constructing around and within the active bakery operations. Austin’s experience working around existing operations proved advantageous as construction could proceed while operations and product quality were not affected.
To insure the client’s 24/7 operations would not be interrupted, a schedule was developed and coordinated with the client, then carried out in a three-phased approach. Temporary walls were built for each phase of the work to allow existing dock equipment to be removed and stored, the new space constructed, dock equipment reinstalled, the space inspected, turned over to the client for occupancy, and then the dock apron finished before the next phase could begin. Juxtaposition of truck traffic and construction equipment were coordinated on a daily basis. This phased approach allowed the client to maintain at least eight fully-functioning dock positions during the construction period and keep operations on schedule.
The third line installation added production of hamburger and hot dog buns at this facility. Production and shipping continued without interruption while the third line was being installed.